Continuous wave coil winding and motor

Abstract

The application discloses a continuous wave winding and a motor, which comprises a winding and a winding flat wire, the winding flat wire is wound in 6 layers and 48 slots along the circumferential direction, and each branch is not connected and overlapped with each other, the winding comprises three phases, the three phases are a U-phase winding, a V-phase winding and a W-phase winding, the U-phase winding, the V-phase winding and the W-phase winding are all wound by 8 coils, the V-phase winding is obtained by rotating 4 slot positions of the U-phase winding along the increasing direction of the slot position, and the W-phase winding is obtained by rotating 2 slot positions of the U-phase winding along the increasing direction of the slot position. The continuous wave winding flat wire can greatly reduce the welding points of the stator manufacturing, reduce the manufacturing process, reduce the risk points, and the motor has high reliability. In addition, because the winding is continuous, the end part is low, the heat generation is less and uniform, the axial distance of the motor is shortened, and the power density of the motor is improved.

Description

Technical Field

[0001] This invention belongs to the field of flat wire motor technology, and specifically relates to a continuous wave winding and motor. Background Technology

[0002] With the continuous development of new energy technologies, motor technology has also advanced rapidly. Currently, most motors on the new energy market are hairpin-type flat wire motors, whose stators mainly consist of a stator core and flat wire windings. The motor stator requires processes such as cutting, shaping, inserting, and welding enameled wire to be manufactured. However, this process has the following problems:

[0003] 1. Motor stators are difficult to manufacture and have a high failure rate;

[0004] 2. Increased end distance, low material utilization, severe heat generation, and low motor efficiency and power density.

[0005] Furthermore, the flat wire windings need to be first made into a hairpin shape, and then undergo winding forming, stripping, wire insertion, twisting, and welding processes to complete the stator manufacturing. This process has the following problems:

[0006] 1. Too many solder joints and complex manufacturing processes make it difficult to control quality, resulting in high process costs, low manufacturing efficiency, and low reliability.

[0007] 2. The winding welding requires a certain length of straight section, so the winding end of the hairpin motor is relatively high, resulting in low material utilization, occupying the axial distance of the motor, serious heat generation, and low power density. Summary of the Invention

[0008] The main objective of this invention is to provide a continuous wave winding and motor, which solves the problems of excessive solder joints, complex manufacturing process, low material utilization, and severe end heating in existing flat wire hairpin motors.

[0009] To achieve the above objectives, the technical solution adopted by the present invention is as follows: a continuous wave winding, comprising a winding and a winding flat wire, wherein the winding flat wire is wound layer by layer along the circumferential direction through 6 layers and 48 slots, and the branches are not connected or overlapped with each other. The winding comprises three phases, namely U-phase winding, V-phase winding and W-phase winding, and each of the U-phase winding, V-phase winding and W-phase winding is made of 8 coils.

[0010] Furthermore, the V-phase winding is obtained by rotating the U-phase winding by 4 slots relative to it in the direction of increasing slot size.

[0011] Furthermore, the W-phase winding is obtained by rotating the U-phase winding by two slots relative to it in the direction of increasing slot size.

[0012] A continuous wave wound cloth motor is made using any of the continuous wave wound cloth windings described above.

[0013] Compared with the prior art, the present invention has the following beneficial effects:

[0014] 1. The coil of this invention contains a large number of coils with completely identical structures, so the coil forming and manufacturing is simple and does not require the manufacture of various coils with different shapes, thus saving costs. After the coils are prefabricated according to the design requirements, since there is no overlap between the coils, the coils can be easily installed into a complete winding. The winding is manufactured by connecting the head and tail of the coils according to the design branch conditions.

[0015] 2. The continuous wave-wound flat wire form of this invention can significantly reduce the number of solder joints in stator manufacturing, reduce the number of processes in the manufacturing process, reduce risk points, and improve the reliability of the motor.

[0016] 3. Because the windings are continuous, the ends of the present invention are lower, resulting in less and more uniform heat generation. It also shortens the axial distance of the motor and improves the power density of the motor. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the continuous wave winding wiring of the flat wire motor of the present invention;

[0018] Figure 2 This is a three-dimensional schematic diagram of the continuous wave winding of the flat wire motor of the present invention;

[0019] Figure 3 This is a three-dimensional schematic diagram of coils U1 and U3 of the present invention;

[0020] Figure 4 This is a three-dimensional schematic diagram of coils U2 and U4 of the present invention. Detailed Implementation

[0021] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] See Figure 1 and Figure 2 This invention discloses a continuous wave fabric winding, including a winding flat wire, which is wound layer by layer along the circumference through 6 layers and 48 slots. The branches are not connected or overlapped with each other. It can be manufactured separately and then assembled. It has the advantages of convenient manufacturing, compact structure, few solder points and high reliability.

[0023] The specific wiring method in this solution is as follows:

[0024] This winding consists of three phases: U-phase, V-phase, and W-phase. Each of the U-phase winding, V-phase winding, and W-phase winding is made of eight coils.

[0025] When three-phase parallel flat wires are used to wind 6 layers of 48 slots, the pole number is 8. Define xy as the xth layer of the xth slot, where x∈[1,48], y∈[1,6], a~f are the 1-6 layer numbers of the conductor in the slot, and a is the layer located in the slot.

[0026] Taking phase U as an example, the winding sequence of each coil is as follows:

[0027] U1: 19a→14b→7b→2b→43c→38d→31d→26d→19e→14f→7f→2f.

[0028] U2: 43f→2e→7e→14e→19d→26c→31c→38c→43b→2a→7a→14a.

[0029] U3: 20a→13b→8b→1b→44c→37d→32d→25d→20e→13f→8f→1f.

[0030] U4: 44f→1e→8e→13e→20d→25c→32c→37c→44b→1a→8a→13a.

[0031] U5: 43a→38b→31b→26b→19c→14d→7d→2d→43e→38f→31f→26f.

[0032] U6: 19f→26e→31e→38e→43d→2c→7c→14c→19b→26a→31a→38a.

[0033] U7: 44a→37b→32b→25b→20c→13d→8d→1d→44e→37f→32f→25f.

[0034] U8: 20f→25e→32e→37e→44d→1c→8c→13c→20b→25a→32a→37a.

[0035] Preferably, this wiring method can be configured with either 4 parallel or 2 parallel connections as needed;

[0036] Reference Figure 1 The winding method of each branch of the U phase in the 4-parallel connection method is as follows:

[0037] Branch 1: U1→U2 (19a→14b→7b→2b→43c→38d→31d→26d→19e→14f→7f→2f→43f→2e→7e→14e→19d→26c→31c→38c→43b→2a→7a→14a).

[0038] The current in this branch flows in from 19a and flows out from 14a.

[0039] Branch 2: U3→U4 (20a→13b→8b→1b→44c→37d→32d→25d→20e→13f→8f→1f→44f→1e→8e→13e→20d→25c→32c→37c→44b→1a→8a→13a). Current in this branch flows in from 20a and out from 13a.

[0040] Branch 3: U5→U6 (43a→38b→31b→26b→19c→14d→7d→2d→43e→38f→31f→26f→19f→26e→31e→38e→43d→2c→7c→14c→19b→26a→31a→38a). Current in this branch flows in from 43a and out from 38a.

[0041] Branch 4: U7→U8 (44a→37b→32b→25b→20c→13d→8d→1d→44e→37f→32f→25f→20f→25e→32e→37e→44d→1c→8c→13c→20b→25a→32a→37a). Current in this branch flows in from 44a and out from 37a.

[0042] Reference Figure 1 The winding method of each branch of the U phase in the 2-parallel connection method is as follows:

[0043] Branch 1: U1→U2→U5→U6 (19a→14b→7b→2b→43c→38d→31d→26d→19e→14f→7f→2f→43f→2e→7e→14e→19d→26c→31c→38c→43b→2a→7a→14a→43a→38b→31b→26b→19c→14d→7d→2d→43e→38f→31f→26f→19f→26e→31e→38e→43d→2c→7c→14c→19b→26a→31a→38a). Current in this branch flows in from 19a and out from 38a.

[0044] Branch 2: U3→U4→U7→U8 (20a→13b→8b→1b→44c→37d→32d→25d→20e→13f→8f→1f→44f→1e→8e→13e→20d→25c→32c→37c→44b→1a→8a→13a→44a→37b→32b→25b→20c→13d→8d→1d→44e→37f→32f→25f→20f→25e→32e→37e→44d→1c→8c→13c→20b→25a→32a→37a). Current in this branch flows in from 20a and out from 37a.

[0045] Furthermore, the V-phase winding is rotated four slots relative to the U-phase winding in the direction of increasing slot size.

[0046] Furthermore, the W-phase winding is rotated two slots relative to the U-phase winding in the direction of increasing slot size.

[0047] Furthermore, according to the above wiring method, where U1 and U3 have similar structures, after installation they are adjacent coils that do not overlap or connect. The coils are arranged as follows: Figure 3 As shown; U2 and U4 also have similar structures, and after installation, they are adjacent coils that do not overlap or connect. The coils are arranged as follows. Figure 4 As shown.

[0048] Furthermore, the coil structures of U5, U6, U7, and U8 are completely identical to those of U1, U2, U3, and U4.

[0049] Furthermore, U5=U1; U6=U2; U7=U3; U8=U4.

[0050] Because this coil contains a large number of coils with completely identical structures, the coil forming and manufacturing process is simple. There is no need to manufacture various coils with different shapes, which saves costs. After the coils are prefabricated according to the design requirements, since there is no overlap between the coils, the coils can be easily installed into a complete winding. The winding is completed by connecting the head and tail of the coil according to the design branch situation.

[0051] The continuous wave-wound flat wire form of this invention can significantly reduce the number of solder joints in stator manufacturing, reduce the number of processes in the manufacturing process, reduce risk points, and improve the reliability of the motor.

[0052] Because the windings are continuous, the ends of the device are lower, resulting in less and more uniform heat generation. This also shortens the axial distance of the motor and increases the power density of the motor.

[0053] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0054] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A continuous wave fabric winding, characterized in that: It includes windings and winding flat wires. The winding flat wires are wound in 6 layers and 48 slots along the circumferential direction. The branches are not connected or overlapped with each other. The windings include three phases: U-phase winding, V-phase winding and W-phase winding. Each of the U-phase winding, V-phase winding and W-phase winding is made of 8 coils.

2. The continuous wave fabric winding according to claim 1, characterized in that: The V-phase winding is obtained by rotating the U-phase winding by 4 slots relative to it in the direction of increasing slot size.

3. A continuous wave fabric winding according to claim 1, characterized in that: The W-phase winding is obtained by rotating the U-phase winding by two slots relative to it in the direction of increasing slot size.

4. A continuous wave wound cloth motor, characterized in that: It is made using the continuous wave fabric winding as described in any one of claims 1-3.

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